Spindle assembly with mechanical fuse for surgical instruments

ABSTRACT

A spindle assembly of a surgical instrument includes a body and a cutter pin. The body has at least one wall forming first and second channels therein. The cutter pin is disposed within the second channel and operably coupled to a knife rod extending therethrough and is operatively coupled at its distal end to a knife. When the knife rod is moved between a retracted position and a deployed position, the spindle assembly is moved between a first and a second position along the shaft. The cutter pin is configured to deform and exit the body when the knife is deployed and disposed in a trapped condition and in response to an applied force, thereby decoupling the knife from the spindle assembly.

CROSS-REFERENCE TO RELATED APPLICATION(S)

The present application is a continuation application of U.S. patentapplication Ser. No. 15/383,503, filed on Dec. 19, 2016, which is adivisional application of U.S. patent application Ser. No. 13/441,169,filed on Apr. 6, 2012 (now U.S. Pat. No. 9,526,563), the entire contentsof each of which are incorporated by reference herein.

BACKGROUND

The present disclosure relates to surgical instruments. Moreparticularly, the present disclosure relates to a spindle assemblyhaving a mechanical fuse that causes a surgical instrument to failsafeunder certain surgical conditions.

TECHNICAL FIELD

Electrosurgical instruments, e.g., forceps, utilize both mechanicalclamping action and electrical energy to effect hemostasis by heatingtissue and blood vessels to coagulate, cauterize and/or seal tissue. Asan alternative to open forceps for use with open surgical proceduresthat require relatively large incisions, many modern surgeons useendoscopic or laparoscopic instruments for remotely accessing organsthrough smaller, puncture-like incisions or natural orifices. As adirect result thereof, patients tend to benefit from less scarring andreduced healing time.

Many endoscopic surgical procedures require cutting or ligating bloodvessels or vascular tissue. Due to the inherent spatial considerationsof the surgical cavity, surgeons often have difficulty performingtraditional methods of controlling bleeding, e.g., suturing, clampingand/or tying-off transected blood vessels. By utilizing an endoscopicelectrosurgical forceps, a surgeon can cauterize, coagulate/desiccate,staple, and/or reduce or slow bleeding by applying electrosurgicalenergy to tissue through a pair of opposing jaw members and controllingthe intensity, frequency and duration of the electrosurgical energyapplied. The surgeon can seal larger vessels or tissue by clamping thevessels or tissue with the jaw members and applying electrosurgicalenergy to the clamped tissue. Typically, after a vessel or tissue issealed, the surgeon advances a knife to sever the sealed tissue disposedbetween the opposing jaw members.

The forceps is typically provided with several actuators. A firstactuator, such as a lever, controls opening and closing of the jawmembers relative to one another for clamping and releasing tissue. Asecond actuator, such as a footswitch, controls application of theelectro surgical energy via the jaw members. A third actuator, such as atrigger, controls deployment of the knife. The forceps may be configuredwith a lockout feature that prevents deployment of the knife unless thejaw members are closed. Additionally, when the knife is deployed, thelockout feature may prevent the jaw members from opening.

SUMMARY

One aspect of the present disclosure relates to a surgical instrumenthaving a housing and a shaft having a proximal end positioned within thehousing and a distal end positioned remote from the housing. The shafthas a longitudinal axis defined between the proximal and distal ends. Apair of jaw members is operably coupled to the distal end of the shaft.A movable knife rod is at least partially disposed within the shaft. Aknife is operably coupled to a distal end of the knife rod. An actuatoris operably coupled to the jaw members and moveable relative to thehousing between a first position and a second position for moving thejaw members between an open position and a substantially closedposition.

A movable spindle assembly is provided which has a body which has atleast one wall defining first and second channels therein. The firstchannel has a longitudinal orientation through which the shaft and kniferod extend. The second channel has a different orientation than thefirst channel and is in communication with the first channel. A cutterpin is disposed within the second channel and operably coupled to theknife rod.

A trigger is operably coupled to the spindle assembly and moveablerelative to the housing between a first position and a second positionfor moving the spindle assembly and the knife between a retractedposition in which the knife is retracted within the shaft and a deployedposition in which at least a portion of the knife extends beyond adistal end of the shaft between the jaw members. When the knife isdeployed and disposed in a trapped condition, the cutter pin isconfigured to deform and exit the spindle assembly body in response toan applied force, thereby allowing the knife to move independent of thespindle assembly.

The cutter pin may exit the second channel and further exit the spindleassembly via the first channel. The wall(s) may include a wall thatdefines the second channel, wherein the wall may be provided with achamfer that facilitates the exit of the cutter pin from the secondchannel. One of the wall(s) may be deformable for facilitating exit ofthe cutter pin from the spindle assembly. The spindle assembly mayinclude a spindle sleeve and a spindle cap that define a gaptherebetween when assembled that forms the second channel.

Deformation of the cutter pin may include folding of the cutter pinabout the knife rod to secure the cutter pin to the knife rod. Thesurgical instrument may further include a rotation assembly configuredto rotate the shaft with the knife rod and the cutter pin, wherein thesecond channel may have an annular shape that accommodates rotation ofthe cutter pin. A radius of the second channel may be normal to thelongitudinal axis of the shaft. Operation of one of the trigger or theactuator may cause application of the force to the spindle assembly tomove the spindle assembly away from the cutter pin when the knife is ina trapped condition.

According to another aspect of the disclosure, a spindle assembly of asurgical instrument is provided. The spindle assembly includes a bodyand a cutter pin. The body has at least one wall forming first andsecond channels therein. The first channel has a first orientation andreceives a shaft extending therethrough. The second channel has a secondorientation different than the first orientation and is in communicationwith the first channel. The cutter pin is disposed within the secondchannel and is operably coupled to a knife rod that extends through theshaft and is further operatively coupled at its distal end to a knife.

When the knife rod is moved between a retracted position in which theknife is retracted within the shaft and a deployed position in which theknife is deployed and extends at least partially beyond a distal end ofthe shaft, the spindle assembly is moved between a first position and asecond position along the shaft. The cutter pin is configured to deformand exit the body when the knife is deployed and disposed in a trappedcondition and in response to an applied force, thereby decoupling theknife from the spindle assembly.

The cutter pin may exit the second channel and exits the body via thefirst channel. At least one of the walls that defines the second channelmay be provided with a chamfer that facilitates the exit of the cutterpin from the second channel. At least one of the wall(s) may bedeformable for facilitating exit of the cutter pin from the spindleassembly. The spindle assembly may include a spindle sleeve and aspindle cap that form a gap therebetween when assembled that forms thesecond channel.

Deformation of the cutter pin may include folding of the cutter pinabout the knife rod to secure the cutter pin to the knife rod. Thesecond channel may have an annular shape that accommodates rotation ofthe cutter pin. A radius of the second channel may be normal to thelongitudinal axis of the shaft. The force may be applied to the spindleassembly in response to operation of an actuator of the surgicalinstrument.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the present disclosure are described herein withreference to the drawings, wherein:

FIG. 1A is a perspective view of a forceps including an end effectorassembly in accordance with an embodiment of the present disclosurewherein jaw members of the end effector assembly are disposed in anopened position;

FIG. 1B is a perspective view of the forceps shown in FIG. 1A whereinthe jaw members are disposed in a closed position;

FIG. 1C is an enlarged perspective view of the end effector assembly ofthe forceps shown in FIG. 1A with a knife shown in broken line;

FIG. 2 is a side view of a handle assembly of the forceps of FIG. 1Awherein a portion of a housing has been removed to show internalcomponents of the handle assembly, the handle assembly including a leverand a trigger illustrating a passive lockout feature;

FIG. 3 is a side view of the handle assembly shown in FIG. 2 wherein thelever and trigger illustrating a passive kickback feature;

FIG. 4 is a side view of the handle assembly shown in FIG. 2 wherein thelever, trigger and the spindle assembly are each disposed in an actuatedposition;

FIG. 5 is an enlarged perspective view of the spindle assembly of FIGS.2-4;

FIG. 6 is a partially exploded perspective view of the spindle assemblyof FIG. 5;

FIG. 7 is a cross-sectional perspective view of the spindle assembly ofFIG. 5;

FIG. 8 is a cross-sectional side view of the spindle assembly of FIG. 5with a cutter pin in an initial position, wherein a failsafe conditionhas not occurred;

FIG. 9 is a cross-sectional side view of the spindle assembly of FIG. 5with the cutter pin in an intermediate position, exiting the spindleassembly, when the failsafe condition has occurred; and

FIG. 10 is a cross-sectional side view of the spindle assembly of FIG. 5with the cutter pin in an advanced position, having exited the spindleassembly, when the failsafe condition has occurred.

DETAILED DESCRIPTION

The present disclosure provides a mechanical fuse for a surgical forcepswhich may be used during device lockup in which jaws of the surgicalforceps have closed with a knife in a deployed position such that theknife cannot be retracted. When device lockup occurs, a surgeon mayactivate the mechanical fuse by applying a force to a lever thatoperates the jaws, or to a trigger that operates the knife, causing theforceps to fail safe. Once the forceps fails safe the knife may be movedto a retracted position for safe removal of the forceps from thesurgical site.

Embodiments of the present disclosure are described in detail withreference to the drawing figures wherein like reference numeralsidentify similar or identical elements. As used herein, the term“distal” refers to a portion of an apparatus that is further from auser, while the term “proximal” refers to a portion of the apparatusthat is closer to a user.

Turning now to FIGS. 1A-1C, forceps 10 is an example of an instrumentfor use in accordance with the present disclosure. Forceps 10 includes ahousing 20, a handle assembly 30, a lever assembly 40, a triggerassembly 60, a rotating assembly 70, and an end effector assembly 100.Forceps 10 further includes a shaft 12 having a distal end 14 thatmechanically engages end effector assembly 100 and a proximal end 16that mechanically engages housing 20. The shaft 12 defines alongitudinal axis X-X extending therethrough. Alternatively, anysurgical instrument having an actuator operable to control one or morefunctions of an end effector assembly may be provided.

End effector assembly 100 includes a pair of opposing jaw members 110and 120. End effector assembly 100 is designed as a unilateral assembly,i.e., jaw member 120 is fixed relative to the shaft 12 and jaw member110 is moveable about a pivot 103 relative to jaw member 120. However,either, or both jaw members 110, 120 may be moveable with respect to theshaft 12. In any of these embodiments, jaw members 110, 120 are moveablefrom an open position in which jaw members 110, 120 are spaced apartfrom one another, as shown in FIG. 1A, to a substantially closedposition in which the jaw members 110, 120 are not spaced from oneanother or are closer to one another than in the open position, as shownin FIG. 1B. In the closed position, jaw members 110, 120 aresufficiently close to one another for grasping and manipulating tissue.Further, jaw members 110, 120 include a respective electricallyconductive tissue sealing surface 112, 122. Sealing surfaces 112, 122are disposed in opposed relation relative to one another such that, withjaw members 110, 120 in the closed position grasping tissuetherebetween, electrosurgical energy may be supplied to one or both ofsealing surfaces 112, 122 of jaw members 110, 120, respectively, to sealor otherwise treat tissue grasped therebetween.

Jaw members 110, 120 define a longitudinally extending knife channel 130therein, which permits reciprocation of a knife 132 therethrough fordividing tissue grasped between the jaw members 110, 120. Knife 132 isoperatively coupled to a knife rod 134 that is received within alongitudinally oriented channel defined within shaft 12. Knife rod 134is operatively coupled to trigger assembly 60 such that, upon actuationof a trigger 62, the knife 132 is translated from a retracted positionto an extended position wherein at least a portion of the knife 132 isadvanced beyond a distal end of shaft 12 between jaw members 110, 120 tocut tissue grasped therebetween. As described below with reference toFIGS. 3-4, trigger 62 is biased toward an initial position (see FIGS.2-3) by a spring 82, such that upon release of trigger 62, the knife 132is returned to its initial, retracted position. Forceps 10 may bedesigned to withstand about 200-500 knife snapback cycles.

As described further below, a lockout feature prevents the knife 132from being deployed when the jaw members 110, 120 are in the openposition. With reference to FIG. 1C, knife 132 is shown in broken linesto indicate that the lockout feature would prevent knife 132 fromactually being deployed to the position shown when the jaw members 110,120 are in the open position. Additionally, the jaw members 110, 120 areprevented from being opened via the normal course of operation while theknife 132 is deployed.

As described further below, in some circumstances, a device “lockup”condition can occur in which the knife 132 is deployed but trapped orimmobilized between the jaw members 110, 120 when in the closedposition. With the knife “locked up”, the jaw members 110, 120 may notbe able to be opened via the normal course of operation. It may bedifficult to remove the forceps 10 from a surgical site when a devicelockup condition occurs, particularly when the jaw members 110, 120 areclamped about tissue.

The present disclosure provides a mechanical fuse 702 (see FIG. 7),described in detail below, for use during device lockup. The mechanicalfuse 702 allows the forceps 10 to failsafe in a predictable manner andallows the surgeon to open the jaw members 110, 120 and safely disengagethe forceps 10 from the surgical site.

In some embodiments (not shown), one or both of the jaw members 110, 120and/or the knife 132 may be configured to curve to the left or the rightto improve visibility of the jaw members 110, 120 and the tissue duringinteraction with tissue. The knife 132 is guided along knife channel 130to curve in the intended direction.

Rotating assembly 70 is integrally associated with housing 20 and isrotatable in either direction about longitudinal axis X-X to rotate jawmembers 110, 120 with respect to housing 20 about longitudinal axis X-X.Other configurations of rotating assembly 70 are envisioned (e.g., therotating assembly 70 positioned externally from the housing 20).Rotation of rotating assembly 70 causes rotation of shaft 12. Knife rod134 rotates together with shaft 12.

Handle assembly 30 includes an integral handle 32 which extends fromhousing 20, and, in some embodiments (not shown), may be configured toreleasably engage housing 20. Handle assembly 30 is ergonomicallyconfigured such that a surgeon may grasp handle assembly 30 and operatelever assembly 40, trigger assembly 60, and/or rotating assembly 70 witha single hand. Handle assembly 30 may further include a battery pack(not shown) disposed within a battery housing defined in integral handle32 that provides power to forceps 10. The battery pack may be configuredto electrically couple to a generator (not shown) disposed withinhousing 20 for supplying electrosurgical energy to the sealing surfaces112, 122 of jaw members 110 and 120. Alternatively, forceps 10 may beconfigured to be coupled to an external power source (not shown) and/orgenerator (not shown), e.g., via an electrosurgical cable (not shown).

One embodiment of lever assembly 40 is shown including a lever 41pivotably coupled to housing 20 and extending downwardly therefrom.Lever 41 is ultimately connected to drive assembly 90 (FIG. 2). Lever 41and drive assembly 90 mechanically cooperate to impart movement of jawmembers 110 and 120 between the spaced-apart position (FIG. 1A) and theclosed position (FIG. 1B). Other configurations of lever assembly 40 areenvisioned for operating drive assembly 90.

Lever 41 is selectively moveable between an initial position (FIG. 1A),and an actuated position relative to integral handle 32 (FIG. 1B) formoving jaw members 110, 120 between the open position shown in FIG. 1Aand the closed position shown in FIG. 1B. A biasing device, such asspring 42, is compressed when lever 41 is rotated in direction “E”. Thespring 42 (FIG. 2) biases lever 41 toward the initial position shown inFIG. 1A in which lever 41 is spaced-apart from handle 32, and jawmembers 110, 120 are opened to the open position shown in FIG. 1A.

Turning now to FIGS. 2-4, trigger 62 is selectively moveable from aninitial position (FIGS. 2 and 3), wherein trigger 62 is spaced-apartfrom “Y”-shaped plate 44 and knife 132 is retracted, to an actuatedposition (see FIG. 4), wherein trigger 62 is positioned adjacent toplate 44 and knife 132 is deployed. Trigger 62 extends from trigger arm64. Trigger arm 64 is coupled to plate 44 at joint 49 and to spindledrive arm 66 at joint 65. The spindle drive arm 66 is coupled to spindleassembly 80, and a knife biasing spring 82 is disposed distally of thespindle assembly 80. The knife biasing spring 82 is retained between thespindle assembly 80 and a stop 84 that is stationary relative to thehousing 20. Actuation of trigger 62 causes trigger 62 to pivot generallyin direction “E” about joint 49 and joint 65, which, in turn, causesspindle drive arm 66 to translate spindle assembly 80 longitudinally ina distal direction “A” along shaft 12, which, in turn, compresses knifebiasing spring 82 between spindle assembly 80 and the stop 84. Spindleassembly 80 is operatively coupled to knife 132 (FIG. 1C), such thatwhen spindle assembly 80 is moved distally along shaft 12, knife 132deploys.

When trigger 62 is actuated, knife biasing spring 82 exerts a springreturn force F_(sr) against spindle assembly 80. Upon release of thetrigger 62 by the surgeon, spring return force F_(sr) causes trigger 62to return to its initial position and causes the knife 132 to retract.The surgeon can feel the force exerted on trigger 62 by knife biasingspring 82 and typically controls release of the trigger 62 so that knife132 is retracted in a controlled manner without undue acceleration. Ifthe trigger 62 were released in an uncontrolled manner, the knife 132could abruptly return to its retracted position.

FIG. 2 illustrates an exemplary passive safety feature. An exemplarypassive safety feature is described in U.S. patent application Ser. No.13/401,964, filed Feb. 22, 2012 (now U.S. Pat. No. 9,113,940), entitled“TRIGGER LOCKOUT AND KICKBACK MECHANISM FOR SURGICAL INSTRUMENTS,” whichis herein incorporated by reference in its entirety. The passive safetyfeature includes a lockout feature that locks trigger 62 in its initialposition and prevents trigger 62 from being actuated when lever 41 ispositioned in its initial position. The lockout feature thus preventsthe knife 132 from being deployed when jaw members 110, 120 are spacedapart (FIG. 1A). The lockout feature includes lockout lever 48, which iscoupled to plate 44 at joint 47 and to drive lever 46 at joint 45. Whenthe lever 41 is disposed in its initial position, plate 44 and drivelever 46 are arranged such that a distal end 51 of lockout lever 48abuts a proximal face 61 of trigger arm 64. Lockout lever 48 ispositioned such that even when force is applied to trigger 62 in anattempt to actuate trigger 62, such actuation is prevented byinterference with lockout lever 48, thus preventing deployment of knife132.

Other lockout features are envisioned, and the present disclosure is notlimited to the above described lockout feature. For example, the lever41 and trigger 62 may be configured so that when the lever 41 andtrigger 62 are in their respective initial positions, the lever 41, oralternatively a handle that operates the lever 41, abuts the proximalface 61 of trigger 62 and prevents actuation of the trigger 62.

The passive safety feature also includes a passive kickback mechanism,shown in FIG. 3, which may be employed when the spring return forceF_(sr) is insufficient to return trigger 62 to its initial position andretract the knife 132. This may occur when the knife 132 becomesimmobilized. Such immobilization may occur, for example, when knifechannel 130 is exposed to tissue and fluids in the surgical sight andbecomes sticky, interfering with movement of knife 132 within knifechannel 130, when knife 132 becomes misaligned or derailed from knifechannel 130, and/or when jaw members 110, 120 clamp down on the knife132 trapping the knife 132 between the jaw members 110, 120.

In one exemplary scenario in which knife 132 may become trapped betweenjaw members 110, 112, jaw members 110, 120 are first latched onto athick tissue bundle without fully closing and knife 132 is deployed. Jawmembers 110, 120 may lose their grasp and drop off the tissue bundle,slamming shut due to the force applied by spring 42 as the surgeoncontinues to pull the lever 41 in direction “E”. This may cause jawmembers 110, 120 to slam shut on knife 132 while it is still deployed,interfering with return of knife 132 to its initial position.

When the knife 132 is immobilized in a deployed position and the springreturn force F_(sr) is insufficient to retract the knife 132, thesurgeon can use the passive kickback mechanism to retract the knife 132by applying a first manual force to lever 41 and/or trigger 62 indirection “D”. As lever 41 is moved in direction “D”, distal end 51 oflockout lever 48 applies a passive kickback force to the proximal face61 of trigger arm 64, causing trigger 62 to move in direction “D” andknife 132 to retract. However the knife 132 may be trapped, such thatthe application of force by the surgeon is unsuccessful in causingapplication of the passive kickback force, or the passive kickback forceis insufficient to free the knife 132 so that it can retract. When thisoccurs, the lever 41 is immobilized in the actuated position and jawmembers 110 and 120, which are closed and may be clamped on tissue,cannot be opened.

This condition is known as device lockup. When device lockup occurs, thejaw members 110, 120 may be stuck in a closed position while knife 132is trapped in a deployed position. Jaw members 110, 120 may still have agrasp on tissue. When the passive safety mechanism fails to retract theknife 132, the surgeon may apply a second manual force, also referred toas a manual failsafe force, to lever 41 and/or trigger 62 that is evengreater than the first manual force. This manual failsafe force is usedto activate the mechanical fuse 702 and cause the forceps 10 tofailsafe, allowing jaw members 110, 120 to open and release any tissue.

Mechanical fuse 702 includes spindle assembly 80. With reference toFIGS. 5-8, spindle assembly 80 includes a spindle sleeve 504, a spindlecap 502, and a cutter pin 506. Spindle sleeve 504 and spindle cap 502are both of annular shape. When the spindle sleeve 504 and spindle cap502 are assembled, they form a first channel 508 defined therebetweenwhich is oriented along the longitudinal direction. Although in thepresent exemplary embodiment spindle sleeve 504 and spindle cap 502 areshown as separate units, it is envisioned that they could be formed as asingle unit. Shaft 12 is received within and extends through firstchannel 508. Knife rod 134, which is disposed within the longitudinallyoriented channel defined within shaft 12, as described above, is thusalso received within first channel 508.

Spindle sleeve 504 includes a first portion 512 and a second portion514. First portion 512 is formed of cylindrically-shaped wall 511, andsecond portion 514 is formed of cylindrically-shaped wall 513 andannularly-shaped proximal wall 515. An inner surface of wall 511 offirst portion 512 defines a portion of channel 508. Second portion 514has a larger external diameter than an external diameter of firstportion 512. An inner surface of cylindrically-shaped wall 513 defines acavity 519 having a larger diameter than that of channel 508.

Spindle cap 502 includes a cap portion 516 and a cylindrical portion 518having cylindrical wall 523. An outer diameter of cylindrical portion518 is dimensioned to fit within cavity 519. Cap portion 516 has anouter diameter that is larger than the diameter of cavity 519 whichprevents cap portion 516 from entering cavity 519. When the spindlesleeve 504 and spindle cap 502 are assembled, channel 508 is formed byan inner surface of wall 523 of cylindrical portion 518 of spindle cap502 and the inner surface of wall 511 of first portion 512 of spindlesleeve 504.

Spindle cap 502 and spindle sleeve 504 have mating features that securespindle cap 502 to spindle sleeve 504 so that cylindrical portion 518 ofspindle cap 502 remains seated within the portion of channel 508 formedby second portion 514 of the spindle sleeve 504. In the embodiment shownin FIGS. 6-10, the mating features include a rib 520 provided on theexternal surface of wall 523 of cylindrical portion 518 of spindle cap502 that is configured to match and interface with a correspondinggroove 522 provided on the inner surface of wall 513 of second portion514 of the spindle sleeve 504 that defines cavity 519. Other matingfeatures are envisioned.

Since wall 523 of cylindrical portion 518 of cap 502 is shorter thanwall 513 of second portion of spindle sleeve 504, a gap is formedbetween proximal end 525 of wall 523 and a distal surface 529 ofproximal wall 515. The gap forms an annularly-shaped second channel 526in which cutter pin 506 is disposed. Cutter pin 506 is securely heldwithin second channel 526 under normal operating conditions, thuscoupling cutter pin 506 to spindle sleeve 504. As shown, second channel526 is in communication with first channel 508, and first channel 508passes through second channel 526.

Second channel 526 is oriented in the transverse direction such that aradius of the annular second channel 526 is normal to the longitudinalaxis of the first channel 508. The annular configuration of secondchannel 526 allows cutter pin 506 to rotate within spindle sleeve 504when knife rod 134 is rotated (e.g., when shaft 12 and knife rod 134 arerotated by rotating assembly 70, as described above). Thus, withadditional reference to FIGS. 2-4, actuation of trigger 62 effectslongitudinally-directed movement of spindle assembly 80 which causeslongitudinally-directed movement of cutter pin 506 and substantiallyequivalent longitudinally-directed movement of knife rod 134. In anotherembodiment, forceps 10 is not provided with a rotating assembly 70 andsecond channel 526 may be designed to have a different configuration,such as a linear configuration.

Cutter pin 506 is operatively coupled to knife rod 134 and to spindlesleeve 504, thus operatively coupling knife rod 134 to spindle assembly80. With respect to the coupling of cutter pin 506 to knife rod 134,cutter pin 506 extends transversely through an aperture 521 provided inknife rod 134. Other methods of configuring cutter pin 506 and couplingcutter pin 506 to knife rod 134 are envisioned. For example, cutter pin506 may be configured as one or more spikes secured to an externalsurface of shaft 12 or extending from a ring that is mounted on andsecured to the external surface of shaft 12.

Knife biasing spring 82 is disposed externally from channel 508 andabuts an external distal face 524 of spindle cap 502. In otherembodiments (not shown), the proximal end of knife biasing spring 82 isdisposed within channel 508 and abuts an internal, distal side of aproximal wall of spindle cap 502. When knife 132 is deployed, knifebiasing spring 82 exerts the spring return force F_(sr) against spindleassembly 80 that urges spindle assembly 80 toward its initial position.Distal advancement of the spindle assembly 80 and deployment of knife132 requires the application of a force that exceeds the spring returnforce F_(sr). Activation of trigger 62 results in application of a forceto spindle assembly 80 in direction “A” that exceeds the spring returnforce F_(sr) and causes distal advancement of the spindle assembly 80and deployment of knife 132.

In operation, trigger 62 can only be actuated when lever 41 is rotatedsufficiently in direction “E” to begin compressing spring 42. Thesurgeon actuates trigger 62 by moving trigger 62 in a proximal direction“E” which causes trigger 62 to pivot. This causes spindle drive arm 66(FIGS. 2-4) to move spindle assembly 80 in a distal direction “A” whichmoves the knife rod 134 in the distal direction “A”, thereby causingdeployment of knife 132. When the surgeon releases trigger 62, knifebiasing spring 82 causes the spindle assembly 80, and thus knife rod 134and knife 132, to return to their initial positions. However, asdescribed above, device lockup may occur if a trapping force F_(trap)exceeding spring return force F_(sr) and the passive kickback force isexerted on knife 132 and prevents the knife 132 from moving towards itsinitial position.

In this situation, mechanical fuse 702 allows the forceps 10 to failsafeso that the pair of jaw members 110, 120 may return to its initial, openposition and the forceps 10 can be removed from the surgical site. Whenforceps 10 is locked up, the surgeon may apply a manual force to lever41 and/or trigger 62 sufficient to overcome trapping force F_(trap) andremove knife 132 from its trapped position. However, if the surgeon doesnot succeed in releasing the knife 132 from its trapped position byapplying the manual force, the surgeon may apply a manual failsafeforce, larger than the first manual force, to the lever 41 or trigger 62to induce the forceps 10 to failsafe as described below.

With reference to FIGS. 2-4 and 7-10, the mechanical fuse 702 andfailsafe mode are described. Device lockup may occur during surgicalusage when trigger 62 and lever 41 are in the positions shown in FIG. 4and cutter pin 506 is in the position shown in FIGS. 7 and 8. If knife132 is trapped and does not return to its initial position via thepassive kickback mechanism or the lockout mechanism, and the jaw members110, 120 are locked in a closed position, the surgeon may apply a largemanual failsafe force to trigger 62.

When the surgeon applies a large manual failsafe force to trigger 62 indirection “D”, trigger 62 pivots about joint 49 and trigger arm 64pivots about joint 49, thus pulling spindle drive arm 66 in proximaldirection “B”. Spindle drive arm 66 pulls spindle assembly 80 indirection “B”. This causes proximal end 525 of spindle cap's 502cylindrical portion's 518 wall 523 to exert a force F_(spindle) againstcutter pin 506. When force F_(spindle) exceeds a threshold failsafeforce F_(fs), which is the amount of force needed to bend cutter pin506, cutter pin 506 fails by folding against knife rod 134 as shown inFIG. 10 and extruding out from spindle assembly 80 via channel 508.Cutter pin 506 bends at a middle portion 542 so that when cutter pin 506is folded, the middle portion 542 is distally located relative to theends 540 thereof, and the middle portion 542 backs out of the secondchannel 526 through first channel 508. As cutter pin 506 backs out offirst channel 508, spring 82 exerts spring return force F_(sr) onspindle cap 502, pushing spindle assembly 80 in direction “B”.

Cutter pin 506 and spindle cap 502 are each configured to allow thefailure of cutter pin 506 during device lockup but not during normal useof forceps 10. Cutter pin 506, wall 513 of the cylindrical portion ofspindle cap 502, and cylindrical wall 523 of cylindrical portion 518 ofspindle sleeve 504 are formed of a deformable material that allowscutter pin 506 to bend, and walls 513 and 523 to flex in a radiallyoutward direction “C” to accommodate the extrusion of cutter pin 506through the channel 508. Alternatively or additionally, walls 513 and523 may be formed of a plastic that may deform and/or yield toaccommodate the extrusion of cutter pin 506.

Additionally, cylindrical portion 518 of spindle cap 502 has a chamferedportion wherein an inner face 527 of cylindrical wall 523 is sloped tofacilitate the extrusion of cutter pin 506. Force F_(spindle) pullsspindle assembly 80 in a proximal direction “B” while cutter pin 506 isimmobilized due to the immobilization of knife 132 and knife rod 134.Cutter pins ends 540 are forced against the proximal end 525 ofcylindrical wall 523. Since middle portion 542 of cutter pin 506 iscoupled to immobilized knife rod 134, the cutter pin 506 is pulled atmiddle portion 542 which enters channel 508. Due to the chamfered shapeof cylindrical wall 523, channel 508 has a diameter that decreases inthe distal direction “A” to a diameter that is slightly larger than theouter diameter of shaft 12 and suited to accommodate shaft 12. As middleportion 542 enters channel 508, the inner face 527 of cylindrical wall523 pushes against ends 540 of cutter pin 506 causing cutter pin 506 tofold. Cylindrical wall 523 and cap portion 516 deflect enough to allowfolded cutter pin 506 to exit first channel 508.

It is contemplated that in another embodiment the electrosurgicalinstrument 10 is configured so that knife biasing spring 82 biases theknife 132 to be disposed in a deployed position, where activation oftrigger 62 moves the knife to a retracted position. In this embodiment,the cutter pin 506 may be extracted through a proximal end of spindleassembly 80. The proximal wall defining the second channel 526 would beshaped, such as with a chamfer, to facilitate extrusion of cutter pin506 from the second channel 526. More specifically, a distal surface 529of proximal wall 515 would be shaped with a chamfer. The walls of thefirst portion 512 of the first channel 508 may be configured to flexradially in direction “C” to facilitate extrusion of cutter pin 506 fromthe first channel 508 and from spindle assembly 80.

Since failure of cutter pin 506 is undesired during normal use offorceps 10, failsafe force F_(fs) must be greater than any forcesexerted on cutter pin 506 during normal use, including less than typicalcircumstances. Such less than typical circumstances may include whenthere is interference with movement of knife 132 but the knife 132 canstill be retracted, albeit with more force than the spring return forceF_(sr).

This may occur, for example, when knife channel 134 is exposed to tissueand fluids in the surgical sight and becomes sticky, interfering withmovement of knife 132 within knife channel 134. In this circumstance,spring return force F_(sr) exerted by biasing spring 82 may beinsufficient to retract knife 132, and the surgeon may need to apply aforce greater than spring return force F_(sr) to retract knife 132. Thesurgeon may do this by applying force to trigger 62 and/or lever 41 formoving trigger 62 in direction “D”. However, as long as knife 132 is nottrapped and can still be retracted by application of force to trigger 62by the surgeon, cutter pin 506 should remain engaged in spindle assembly80 and forceps 10 should not failsafe. Therefore, failsafe force F_(fs)may be selected to be large enough to prevent forceps 10 from failingsafe in such a circumstance. In one embodiment, failsafe force F_(fs) is20 lbf.

In another circumstance, the surgeon may unintentionally release thetrigger 62 while the knife 132 is deployed and possibly engaged, but notstuck, in tissue at the surgical site. Knife biasing spring 82 wouldapply spring return force F_(sr) to spindle assembly 80, moving spindleassembly 80 and knife 132 in direction “B” in an accelerating manner andsnapping trigger 62 back to its initial position. Accordingly, F_(fs)may be selected to be sufficiently greater than F_(sr) to avoid failureof the cutter pin 506 upon release of trigger 62 In one embodiment, thespring return force F_(sr) is much less than 20 lbf, even during a knifesnapback condition.

Cutter pin 506, wall 513, and wall 523 are configured to set failsafeforce F_(fs) at a desired value. Selection of the materials used to formcutter pin 506, wall 513, and wall 523, and their respective shapes maybe calculated or determined empirically to achieve the selected failsafeforce F_(fs). Selection of the materials forming cutter pin 506, wall513, and wall 523 includes selecting a material that has a desireddegree of resilience and selecting the thickness and shape of thematerial used. The failsafe force F_(sr) may also be tuned by adjustingheat treatment conditions of cutter pin 506.

In one embodiment, cutter pin 506 is formed of 300 series stainlesssteel. The cutter pin 506, wall 513, and wall 523 may be formed withfeatures that promote folding of cutter pin 506 and outward deflectionof walls 513 and wall 523. For example, cutter pin 506 may be scored orhave a decreased thickness at a location of the cutter pin 506 wherefolding is desired.

In one embodiment, walls 513 and 523 are formed of a deformable plasticmaterial, such as nylon. Walls 513 and 523 may be formed with adecreased thickness at a location of walls 513 and 523 where deflectionis desired. Additionally, the slope of inner face 527 may be selected sothat extrusion of cutter pin 506 will occur under the desiredconditions.

Cutter pin 506 fails in a safe and predictable way, remaining secured toshaft 12 and knife rod 134 by the folded ends 540 as depicted in FIG.10. Thus, cutter pin 506 cannot fall out of forceps 10, and the risk offoreign material falling into the surgical site is reduced. The failureof cutter pin 506 causes cutter pin 506 to decouple from spindleassembly 80. Once cutter pin 506 is decoupled from the spindle assembly80, the trigger 62 is decoupled from knife rod 134 and knife 132. Kniferod 134 and knife 132 are safely retained within shaft 12. A stop member(not shown) may be provided on knife 132, knife rod 134, and/or shaft 12that prevents knife 132 from exiting shaft 12 at the shaft 12's distalend. Spring return force F_(sr) (exerted by biasing spring 82) returnstrigger 62 to its initial position, thus allowing the surgeon to operatelever 41 to move jaw members 110, 120 to their open position and releaseany tissue that was grasped so that forceps 10 can be removed from thesurgical site.

From the foregoing and with reference to the various figure drawings,those skilled in the art will appreciate that certain modifications canalso be made to the present disclosure without departing from the scopeof the same. While several embodiments of the disclosure have been shownin the drawings, it is not intended that the disclosure be limitedthereto, as it is intended that the disclosure be as broad in scope asthe art will allow and that the specification be read likewise.Therefore, the above description should not be construed as limiting,but merely as exemplifications of particular embodiments. Those skilledin the art will envision other modifications within the scope and spiritof the claims appended hereto.

1-18. (canceled)
 19. A spindle assembly of a surgical instrument,comprising: a body configured to operably couple to a trigger of asurgical instrument and slidably receive a shaft of the surgicalinstrument; and a cutter pin operably engaged to the body and configuredto connect to a knife rod of the surgical instrument, wherein at leastone of the cutter pin or the body is configured to deform uponapplication of a threshold amount of force on the cutter pin by the bodyin a proximally-oriented direction and detach the cutter pin and thebody from one another.
 20. The spindle assembly according to claim 19,wherein the cutter pin extends transversely relative to a longitudinalaxis defined by the body.
 21. The spindle assembly according to claim20, wherein the cutter pin has two opposing ends connected to the body.22. The spindle assembly according to claim 21, wherein the two opposingends of the cutter pin are configured to deform upon application of thethreshold amount of force on the cutter pin by the body in theproximally-oriented direction.
 23. The spindle assembly according toclaim 22, wherein deformation of the cutter pin includes folding the twoopposing ends of the cutter pin relative to an intermediate portion ofthe cutter pin.
 24. The spindle assembly according to claim 19, whereinthe cutter pin is disposed within the body.
 25. The spindle assemblyaccording to claim 19, wherein the body includes: a spindle sleeve; anda spindle cap secured to the spindle sleeve, the cutter pin having twoopposing ends disposed in a gap defined between the spindle sleeve andthe spindle cap.
 26. The spindle assembly according to claim 25, whereinthe spindle cap has a proximally-oriented chamfered surface disposedadjacent the two opposing ends of the cutter pin.
 27. The spindleassembly according to claim 26, wherein the spindle sleeve has a distalportion configured to flex in response to application of the thresholdamount of force on the two opposing ends of the cutter pin by thechamfered surface of the spindle cap in the proximally-orienteddirection.
 28. A surgical instrument, comprising: a housing; a shafthaving a proximal portion coupled to the housing and a distal portion; apair of jaw members operably coupled to the distal portion of the shaft;a movable knife rod at least partially disposed within the shaft; and aspindle assembly including: a body disposed about the proximal portionof the shaft; and a cutter pin coupled to the knife rod; and a triggeroperably coupled to the body such that an actuation of the triggeraxially moves the body, wherein at least one of the cutter pin or thebody is configured to deform upon application of a threshold amount offorce on the cutter pin by the body in a proximally-oriented directionand detach the cutter pin and the body from one another.
 29. Thesurgical instrument according to claim 28, wherein the cutter pinextends transversely relative to a longitudinal axis defined by thebody.
 30. The surgical instrument according to claim 28, wherein thecutter pin has two opposing ends connected to the body.
 31. The surgicalinstrument according to claim 30, wherein the two opposing ends of thecutter pin are configured to deform upon application of the thresholdamount of force on the cutter pin by the body in the proximally-orienteddirection.
 32. The surgical instrument according to claim 31, whereindeformation of the cutter pin includes folding the two opposing ends ofthe cutter pin relative to an intermediate portion of the cutter pin andabout an outer surface of the proximal portion of the shaft.
 33. Thesurgical instrument according to claim 28, wherein the cutter pin isconnected to the body and disposed within a passageway definedlongitudinally through the body.
 34. The surgical instrument accordingto claim 33, wherein the passageway includes a proximal channel and adistal channel in communication with one another, the cutter pindisposed within the distal channel.
 35. The surgical instrumentaccording to claim 34, wherein the proximal channel has a smallerdiameter than the distal channel.
 36. The surgical instrument accordingto claim 28, wherein the body includes: a spindle sleeve; and a spindlecap secured to the spindle sleeve, the cutter pin having two opposingends disposed in a gap defined between the spindle sleeve and thespindle cap.
 37. The surgical instrument according to claim 36, whereinthe spindle cap has a proximally-oriented chamfered surface disposedadjacent the two opposing ends of the cutter pin.
 38. The surgicalinstrument according to claim 37, wherein the spindle sleeve has adistal portion configured to flex in response to application of thethreshold amount of force on the two opposing ends of the cutter pin bythe chamfered surface of the spindle cap in the proximally-orienteddirection.